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Caption Width Bug Passed All Tests by Measuring Text the Screen Never Rendered

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A developer debugging a subtitle system discovered that a width-guard function was measuring caption text in uppercase, even though the actual on-screen captions were displayed in mixed case. Because uppercase glyphs in the Montserrat ExtraBold font render roughly 20% wider, the guard consistently rejected chunks that would have fit on screen comfortably, forcing natural phrases to split into awkward one-word fragments. The flaw originated when caption-width measurement code borrowed an uppercasing step from an unrelated all-caps overlay elsewhere in the same pipeline. Since both the original and corrected code paths passed all automated tests, the bug only surfaced when the developer watched the rendered video output directly. The case illustrates how a measurement function can be logically correct yet produce wrong results when its input does not match the actual rendering context it is meant to validate.

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